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Mercedes Benz 124 SEDAN 260E 2.6L 1987-1992 Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 124 Sedan Engine Variant: 260E Engine Displacement: 2.6L Model Years Covered: 1987, 1988, 1989, 1990, 1991, 1992 Codes Chassis Code: W124 Engine Code:...
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Mercedes Benz 124 SEDAN 260E 2.6L 1987-1992 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
124 Sedan
Engine Variant:
260E
Engine Displacement:
2.6L
Model Years Covered:
1987, 1988, 1989, 1990, 1991, 1992
Codes
Chassis Code:
W124
Engine Code:
M103.981
👋 Introduction
Market Position
Segment:
Executive Sedan
Brand Perception:
Reputation for build quality, durability, safety, and technological innovation.
Competitive Analysis
Competitors:
BMW 5 Series, Audi 100/200, Jaguar XJ, Volvo 740/760.
Key Features
Engineering:
Robust construction, advanced suspension design, refined powertrain.
Design:
Timeless styling, aerodynamic efficiency, spacious and comfortable interior.
Safety:
Pioneering safety features for its era, including advanced crumple zones and ABS.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for the specified Mercedes-Benz 124 Sedan 260E models.
Page Count
Estimated Pages:
Thousands (typical for factory-level service manuals, actual number varies)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanicals, lubrication, cooling, fuel, ignition, emissions, engine management (Bosch KE-Jetronic).
Transmission:
4-speed automatic transmission (722.4) and potentially 5-speed manual transmission (if applicable to 260E variant).
Drivetrain:
Driveshafts, differential, rear axle assembly.
Suspension:
Front suspension (MacPherson struts, control arms), rear suspension (multi-link independent), shock absorbers, springs, bushings.
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System), brake fluid, lines, calipers, master cylinder, parking brake.
Steering:
Power steering system, steering gear, steering column, tie rods.
Electrical:
Battery, charging system, starter, ignition system, lighting, instrumentation, power accessories, wiring diagrams, fuses, relays.
Climate Control:
HVAC system, air conditioning, heater core, blower motor, controls, refrigerant.
Body:
Body panels, doors, hood, trunk, glass, seals, interior trim, exterior trim.
Diagnostic Troubleshooting:
Systematic diagnostic procedures and fault code interpretation for KE-Jetronic and other systems.
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, fluid checks, tune-ups, belt inspections/replacement.
Repair:
Detailed step-by-step instructions for engine, transmission, suspension, brake, steering, and electrical component repairs.
Overhaul:
Complete engine and transmission overhaul procedures, including component specifications and tolerances.
Diagnostics:
Troubleshooting guides for common symptoms and fault diagnosis.
Replacements:
Component replacement procedures for all major systems.
Adjustments:
Settings and adjustments for engine timing, idle speed, and various system components.
Technical Depth
Depth:
Factory-level detail, covering basic maintenance to complete engine and transmission rebuilds.
Diagnostics Level:
Advanced, including diagnostic flowcharts and component testing.
Wiring Diagrams:
Detailed and accurate electrical wiring diagrams for all vehicle systems.
Schematics:
Hydraulic, pneumatic, and electronic schematics where applicable.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (typically OCR'd for keyword searching)
Print Quality
Resolution:
High resolution for clear text and diagrams.
Scalability:
Printable at various sizes without significant loss of quality.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-Cylinder, SOHC
Displacement Liters:
2.6
Bore X Stroke Mm:
82.0 x 80.25
Compression Ratio:
9.2:1
Performance
Horsepower Ps:
160 (approx.)
Torque Nm:
228 (approx.)
Fuel System
Fuel Delivery:
Bosch KE-Jetronic Electronic Fuel Injection
Fuel Type:
Unleaded gasoline
Ignition
Ignition System:
Electronic ignition with knock sensor
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (722.4)
Optional
Transmission Type:
5-Speed Manual (G5/27-5)
Features
Automatic Features:
Lock-up torque converter, electronically controlled hydraulic pressure.
Fluid Specs
Automatic Transmission Fluid:
MB-Approval 236.3 (e.g., Mobil ATF 220, Pentosin ATF 1)
Fluid Capacity
Automatic Transmission Capacity Liters:
Approx. 7.0 (including torque converter)
📐 Dimensions
Exterior
Length Mm:
4740
Width Mm:
1740
Height Mm:
1430
Wheelbase Mm:
2800
Weights
Curb Weight Kg:
1450-1500 (approx., depending on options)
Gross Vehicle Weight Kg:
1950 (approx.)
Wheels Tires
Wheel Bolt Pattern:
5x112
Tire Sizes Standard:
195/65 R15, 205/60 R15
🛡️ Safety Features
Ratings
Era Safety Focus:
High emphasis on passive safety, advanced structural design for its time.
Active Features
ABS:
Standard or optional Anti-lock Braking System (ABS) depending on model year and market.
Passive Features
Airbags:
Driver's side airbag became optional/standard later in the production run.
Seatbelts:
Pre-tensioning front seatbelts.
Body Structure:
Reinforced safety cell, energy-absorbing crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory-installed Becker or Blaupunkt radio/cassette systems, often with optional amplifier and speaker upgrades.
Navigation:
Navigation systems were not standard and were rare options in this era.
Driver Assistance
Cruise Control:
Optional cruise control system.
Connectivity
Connectivity Features:
Limited connectivity by modern standards; primarily focused on vehicle operation and safety.
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
10,000 - 15,000 km or 12 months
Air Filter Interval Km:
20,000 - 30,000 km
Fuel Filter Interval Km:
20,000 - 40,000 km (depending on type)
Spark Plug Interval Km:
30,000 - 50,000 km (depending on type)
Fluid Specifications
Engine Oil Specification:
API SJ/SL or ACEA A3/B3, Viscosity 0W-40, 5W-40, 10W-40, 15W-40 (refer to manual for exact MB-Approval)
Coolant Specification:
MB-Approval 325.0 / 326.0 (Antifreeze/Coolant)
Brake Fluid Specification:
DOT 3 or DOT 4
Known Issues
Wiring Harness:
Degradation of the main engine wiring harness insulation (shredded insulation) is a common issue.
Head Gasket:
Potential for head gasket leaks, especially in high-mileage vehicles.
Suspension Bushings:
Wear and tear on suspension bushings (e.g., control arm bushings, trailing arm bushings) leading to clunks or poor handling.
Climate Control Vacuum Lines:
Aging vacuum lines for the HVAC system can cause flap malfunctions.
Rust:
Susceptibility to rust in common areas like wheel arches, rocker panels, and door bottoms.
📚 Vehicle History
Brand Heritage
Heritage:
Mercedes-Benz's legacy of engineering excellence and luxury motoring.
Model Evolution
W124 Introduction:
The W124 platform was introduced in 1984, representing a significant advancement in automotive engineering and design for Mercedes-Benz.
260E Positioning:
The 260E was positioned as an entry-level luxury sedan within the W124 range, offering a balance of performance and refinement.
Production
Production Years:
1985-1992 (for W124 Sedan, specific 260E variant years apply).
Production Locations
Manufacturing Plants:
Primarily Sindelfingen, Germany, with potential assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Reputation:
The W124 chassis is widely regarded as one of the most over-engineered and durable Mercedes-Benz models ever produced.
Ratings
Reliability Perception:
Consistently high ratings for long-term reliability and build quality in automotive reviews and owner surveys from its era.
Certifications
Industry Recognition:
Praised for its pioneering safety features and engineering advancements by automotive journalists and organizations.
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